Transfer Assembly with Pictures

[FJ60Seth]

Transfer Case Assembly with Pictures

I'm slooowly assembling an h55/Toybox/TCase in my garage. I bought a used tcase to minimize my truck's downtime. I'd never disassembled a tcase so I was stumped for a while understanding how it worked and went back together. I wished I had some pictures of how all the big parts fitted together so I shot some. I'm ready to seal it up, so please let me know if anything doesn't look right.

 

[FJ60Seth]

Front half of the case bolted to toybox (would be the same as transmission)

 

[FJ60Seth]

Idler shaft and (front output shaft ) bearing retainer

 

[FJ60Seth]

Close up of thrust washer, idler shaft, bearings, and spacer.

 

[FJ60Seth]

Idler gear.

 

[FJ60Seth]

Transmission output gear.

 

[FJ60Seth]

Rear output shaft with gears and bearing. I include the bearing numbers because initially I didn't know which bearing went where. I showed my FSM to Mark Algazy and he spewed out the bearing numbers in-between a carb rebuild and a phone call.

 

[FJ60Seth]

I took me a while to understand how the select lever engages the (rear output shaft) shift fork, so I included a picture.

 

[FJ60Seth]

Rear output cluster in place.

 

[FJ60Seth]

All gears in place.

 

[FJ60Seth]

PTO spacer on the transmission output shaft. I was concerned because the bearing didn't completely fit on the remaining part of the shaft.

 

[FJ60Seth]

Ready for the back half of the case.

 

[FJ60Seth]

View from the side.

 

[DaveWest5150]

Seth... the piece that goes thru the case, is the one I was telling you about. make sure, if your going to make a triple stick to use the one from a 62 series.. it make to throw from side to side to front to back. if you have questions... call me I will be up for a bit.
Dave

 

[FJ60Seth]

Back half in place.

 

[TobyB]

Awesome! Thanks for the pix!

t

 

[FJ60Seth]

I hand tightened the (transmission output shaft) lock nut, the bearing felt like it seated, and the nut threaded to the end of the shaft.

 

[FJ60Seth]

I didn't know where this spacer went. Mark A informed me that it's for the speedo gear.

 

[FJ60Seth]

Seth... the piece that goes thru the case, is the one I was telling you about. make sure, if your going to make a triple stick to use the one from a 62 series.. it make to throw from side to side to front to back. if you have questions... call me I will be up for a bit.
Dave

Dave - Thanks for your help and encouragement. I did get the part (the piece that goes in the case) from an FJ62.

 

[dbleon]

This is great! I'll be rebuilding mine in the next couple days... any tip/trick/ things to be careful with?

Did you use a press?

Thanks!!!